Skip to main content
Two AirBorn Rugged Flex Circuit Assemblies

AirBorn Rugged Flexible Circuit Assembly

Each AirBorn Rugged Flexible Circuit Assembly provides a high-reliability interconnect solution for demanding aerospace, defense, medical, industrial and space applications. They are available in single-sided, double-sided, multilayer, rigid-flex, sculptured-flex and high-density edge connections (HDEC) flex formats, delivering durable, lightweight designs that maintain signal integrity under dynamic flexing, vibration and harsh environments. Complete turnkey support, including design, prototyping, assembly and testing, ensures faster development and reliable performance.

Features and Benefits


AirBorn Rugged Flexible Circuit Assemblies deliver advanced interconnect solutions for mission-critical applications across aerospace, defense, robotics and medical devices. Engineered for both static and dynamic flexing, these assemblies enable compact, lightweight designs while maintaining reliable electrical performance under vibration, repeated movement and extreme environmental conditions. Multiple configurations including single- and double-sided, multilayer, rigid-flex, sculptured flex and HDEC flex formats allow engineers to implement complex interconnects without compromising durability or signal integrity.

Material selection and specialized finishes ensure consistent operation in harsh conditions. AirBorn flexible circuit assemblies utilize polyimide, copper alloys and advanced coatings to resist high temperatures, chemical exposure and mechanical stress. Unique technologies such as HDEC enhance routing density and long-term reliability. Custom solutions supporting up to 15 layers meet the most demanding interconnect challenges while minimizing size, weight and complexity.

Each assembly benefits from full-lifecycle support, including initial design consultation, prototyping, assembly, automated inspection, testing and supply chain management. This integrated approach accelerates time to market and reduces development risk, enabling reliable deployment in the harshest operational environments.

Comprehensive Flexible Circuit Configurations

Designing compact, high-density systems can be challenging, especially when multiple PCB components must fit into tight spaces. Each AirBorn Rugged Flexible Circuit Assembly is available in single-sided, double-sided, multilayer, rigid-flex and sculptured-flex formats for maximum design flexibility. These formats enable advanced circuit layouts and effortless integration of multiple components, reducing the need for external connectors and supporting space- and weight-constrained applications.

AirBorn Flex Cable Assembly with an AirBorn W Series connector.

Extreme Environment Materials and Finishes

High-temperature applications can compromise circuit reliability and performance. AirBorn Rugged Flexible Circuit Assemblies use polyimide materials rated for continuous operation up to 230°C. These materials, combined with advanced copper types, alloys and surface finishes, ensure durability, signal integrity and consistent electrical performance in extreme environments.

AirBorn flex cable

Integrated Turnkey Services

Accelerating development without sacrificing quality is a constant challenge in high-reliability applications. The AirBorn Rugged Flexible Circuit Assembly is supported by up-front design engineering, CAD modeling, impedance analysis, and DFX for manufacturability and testing. Combined with rapid prototyping, precision assembly and full supply chain management, this approach ensures fully tested, production-ready solutions with over 95% on-time delivery.

AirBorn Flex Cable Assembly with D-shaped connectors.

Maximizes prototyping accuracy
Production-ready prototyping ensures that each prototype reflects full production standards for accurate performance validation and reduced design iteration time.

Optimizes supply chain management
Comprehensive supply chain management provides seamless coordination from component sourcing to delivery, minimizing delays and ensuring consistent on-time performance.

Enhances assembly precision
Precision hand and automated assembly ensure uniform quality and reliability for both small and large production runs.

Strengthens inspection and testing capabilities
Advanced inspection and testing capabilities ensure every build meets strict quality and reliability standards through comprehensive automated and manual testing.

Supports high-density edge connection options
HDEC options enable reliable signal performance in compact and complex circuit designs by addressing space constraints and electrical interference issues.

Customizes material and plating selection
Custom material and plating options allow engineers to optimize circuit performance for specific application requirements and overcome design limitations.

Meets UL94V-0/UL94V-1 flammability compliance
UL94V-0 and UL94V-1 flammability ratings help ensure safety and regulatory compliance in demanding environments.

Delivers RoHS-capable and lead-free designs
RoHS-capable and lead-free options provide environmentally responsible and regulation-compliant circuit assemblies, minimizing the harmful effects of toxic substances.

Datasheets and Guides


Applications by Industry


This is not a definitive list of applications for this product. It represents some of the more common uses.

Frequently Asked Questions


What are AirBorn Rugged Flexible Circuit Assemblies?

AirBorn Rugged Flexible Circuit Assemblies are flexible printed circuit solutions engineered for high reliability in harsh aerospace, defense, medical, industrial and space applications. They are available in a variety of formats, including single-sided, double-sided, multilayer, rigid-flex, sculptured-flex and HDECs flex.

What flexible circuit configurations are available?

AirBorn Rugged Flexible Circuit Assemblies are offered in single-sided, double-sided, multilayer (up to 15 layers), rigid-flex (two to 15 layers), sculptured flex (one to two layers) and HDEC formats, providing flexibility for compact and complex interconnect designs.

What materials and finishes are used?

Material options include multiple polyimide types (FR, LF, AP and TK), rolled annealed and electro-deposited copper, and beryllium alloy. Surface finishes include ENIG, hard gold, immersion silver/tin, soldermask, PIC, tin/lead and hot air solder leveling.

What are the temperature and environmental ratings?

AirBorn flexible circuit assemblies are engineered to withstand high temperatures, vibration and chemical exposure. Additional shielding options using copper, silver ink epoxy or solid copper provide enhanced EMI protection and environmental resistance.

How does Molex support design and prototyping of AirBorn Rugged Flexible Circuit Assemblies?

Molex provides comprehensive design support, including CAD, schematic capture, impedance modeling, DFX for manufacturability, mock-ups and production-ready prototyping, directly on manufacturing lines.

What assembly and testing capabilities are offered?

Assembly services include SMT and hand soldering for both flex and rigid-flex circuits, epoxy adhesive bonding, wave soldering and conformal coating, along with automated and hand assembly. Testing services include automated optical inspection (AOI), first article inspection (FAI), microsection, impedance, continuity, functionality and environmental testing.

How are quality and reliability ensured?

Quality and reliability are ensured through comprehensive inspection and testing, including AOI, FAI, microsection, impedance, functional and environmental tests. These assemblies are certified to AS9100, ISO 9001, IPC 6013 Class 3, MIL-PRF-31032, MIL-PRF-50884F and UL94V-0/1 standards.

Can the product be customized for specific needs?

Yes, AirBorn Rugged Flexible Circuit Assemblies can be customized for specific requirements, including design, materials, layer counts, surface finishes, assemblies and connector integration.

What industries use these flexible assemblies?

These assemblies are used across aerospace, defense, medical, space, industrial automation, robotics and other demanding applications.